Amptec Research 630ES Manual

RESEARCH
AMPTEC
PHONE [phone]
website http://www.amptec.com
FAX [phone]; TOLL FREE IN USA
Revision D
AMPTEC 630ES
SAFETY IGNITER TESTER
OPERATION/MAINTENANCE MANUAL

1
TABLE OF CONTENTS
_______________________________________________________________
SECTION A: UNPACKING AND INSPECTION
A-1 Introduction to the AMPTEC 630ES
A-2 Unpacking and Inspection
A-3 Opening the 630ES Ohmmeter and Removal of the Lid
A-4 AC Adaptor/ Battery Charger- Power Requirements
A-5 Setup and Use
SECTION B: 630ES Explosive Safety Igniter Tester
SPECIFICATIONS
Table B-2. Specifications
SECTION C: REPLACEMENT, OPTIONAL AND ACCESSORY
ITEMS
C-1 Available Accessories and Options
C-2 Test Lead Sets
SECTION D: OPERATION AND USE
D-1 General
D-2 Front Panel Features and Operation
D-3 Fuse Holder
D-4 4-Wire Resistance Measurement
D-5 Connections
D-6 Failsafe Operation
D-7 Battery Monitoring Circuitry
D-8 Zero Pot

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SECTION E: THEORY OF OPERATION
E-1 General
E-2 Troubleshooting
E-3 Circuit Descriptions
E-4 Analog-to-Digital Converter
E-5 Ohms-to-DC Converter
E-6 Failsafe Design
E-7 Ultra-Safe Power Supply Scheme
Figure E-1. Model 630ES Block Diagram
Figure E-1B Analog-to-Digital Converter Timing Diagram
Figure E-2 Analog Section of IC1 and IC2
Figure E-3. Constant Diagram (Simplified)
Figure E-4. LED Display Pin Functions
SECTION F: ROUTINE MAINTENANCE
F-1 General
F-2 Required Test Equipment
F-3 Calibration Procedure
F-4 Battery Replacement Instructions
A
E-7B Failsafe Current Limiting Circuit

A-1. Introduction to the AMPTEC 630ES
The AMPTEC Series 620A and now the 630
Series Igniter Testers are becoming the
standard in the Explosive Safety Igniter
Circuit Test industry, and are designed to
provide extremely safe and reliable
resistance testing of explosive or volatile
devices. Safety Approvals from various
Safety Boards include, the U.S. Air Force (
620A-4) for generic use on Non-Nuclear
munitions. Some of the devices the 630ES
Failsafe Ohmmeter may be used on include:
fuses, squibs, igniters, explosive bolts,
automobile airbag initiators and many
others.
Essentially, a AMPTEC 630ES is a 4-wire
failsafe digital ohmmeter which has been
designed to reliably use very low test
currents for its resistance measurement.
Additional circuitry proprietary to
AMPTEC RESEARCH is used to ensure
that test current levels do not exceed the
specified "failsafe current" even in a worst-
case component failure situation. The
failsafe feature is tested in every instrument
before shipment.
The 620A and the newer 630 series
represent the latest in ultra-safe Igniter
Tester measurements. The 630ES uses the
same main printed circuit board (PCB) as
the AMPTEC 620A Igniter Tester. The
630ES has been made water-resistant and
has many features which make it useful in a
variety of applications. Please check the
front of this manual for any addendums that
may apply to new 630ESs and 630AN
conversions.
SECTION A: UNPACKING AND INSPECTION
A standard feature of the 630ES is a battery
monitoring circuit that alerts the user it is time to
recharge the batteries. Refer to section D-7 for
more details.
A-2. Unpacking and Inspection
If the shipping carton (box)
appears damaged, request that the
carrier's agent (i.e. UPS) be present
when the unit is unpacked. If the instrument
appears damaged, the carrier's agent should
authorize repairs before the unit is returned to the
factory. Even if the instrument appears
undamaged, it may have suffered internal damage
in transit that may not be evident until the unit is
operated or tested to verify conformance with its
specifications. You may refer to the Functional
Test section of Section D of this manual to help
identify the problem (i.e Test leads etc.) The
630ES has a set of test resistors built-in the
Functional Test Section that can quickly help the
user figure out where the problem is most of the
time. If the unit fails to operate or fails to meet the
performance specifications of Section B, notify
the carrier's agent and the nearest AMPTEC Sales
Office. Retain the shipping carton for the carrier's
inspection. DO NOT return equipment to
AMPTEC RESEARCH or any of its sales offices
prior to obtaining an (RMA) Return Material
Authorization number.
R M A

1
A-3. Opening the 630ES Igniter Tester
and removal of the Lid
When closed, the 630ES Explosive Safety
Igniter Tester has two large O-rings that
provide a very water resistant and on
occasion even an air tight seal. By
pressing down with your palm as
diagramed above you compress the O-ring
in the lid of the 630ES.. This makes it
easier to flip up the release latch. Repeat the
palm press step on the other corner of the
630ES while flipping up the release latch.
At this point the 630ES lid will normally be
able to be raised, and placed in an open lid
state.
If the 630ES doesn’t open after flipping up
the release latches, a change in atmospheric
pressure since the unit was last closed may
be the culprit. Turn the Air Pressure
Equalization or “Purge Valve” counter-
clockwise. Once air-pressure is equalized,
the 630ES can be opened. If the Purge
Valve was opened, return the valve to the
closed state (tighten = clockwise) once the
630ES lid is open. +
The 630ES has a way to remove it’s lid
completely, for example when used in an
indoor laboratory environment. With the
630ES open, remove the units two hinge
pins (hex type) by twisting them. The lid
should come free at the hinge. Once the lid is
removed replace the hinge pins in the hole they
were pulled out of.
A-4. AC/DC Battery Charger - Power
Requirements
The AMPTEC 630ES is powered by an
internal rechargeable heavy-duty nickel-
cadmium battery pack (4 ea D cell - 5.7 AHr).
The battery charge is maintained by an
external AC/DC converter that plugs into a
standard 115VAC receptacle. The AC adapter
provides 9VDC @ 1.1A. The AC Adapter
Battery Charger is configured with a keyed
connector that plugs into the “mating” keyed
connector on the 630ES front panel.
For safety reasons, the battery charger’s keyed
connector blocks access to the test lead
connections that are also part of the

the AC adapter must be connected for 4 hours in
order to fully restore the charge. If you need a
replacement AC/DC Battery Charger for the 630A,
contact the AMPTEC customer service department
and request an option “630DC” Battery Charger.
A-5. Setup and Use
Once the AMPTEC 630ES has had it’s batteries
charged for 12 to 24 hours it is ready for use. The
630ES consumes little power and generates virtually
no heat. Consequently, it may be used in any area
where the environment does not exceed the
specifications of Table B-2.
Avoid exposing the 630ES Explosive Safety Igniter
Tester to extremes of temperature which will affect
accuracy and shorten battery life-span.
630ES Explosive Safety Igniter Tester keyed
connector. In this way the user may not ever be able
to connect any test leads while the unit is charging.
The 630ES is designed so it is virtually impossible to
be powered (in operating - measurement mode)
directly from the AC line adapter. As an additional
note, the 630ES main power switch must also be in
the “Off/Charging” mode in order for the connected
battery charger to recharge the 630ES’s batteries.
For customers using 220VAC 50 HZ AC line power
for running the battery charger, please inform
AMPTEC’s sales department at the time of your
order and the appropriate adaptor will be included
with the 630ES Failsafe Ohmmeter shipment for an
additional fee.
A fully charged battery pack may power the 630ES
for approximately 8 to 10 hours before requiring a
recharge. Amptec installs a quality set of 4 each
Heavy Duty (5700 mAHr) Ni-Cad batteries. The
620A will also operate on a 4000 mAhr D cell Ni-
Cads with a shortened operating time between
charges.
The “Power” switch has two separate modes. The
“ON” position supplies internal battery isolated
power to operate the 630ES when they are charged.
If you turn on the 630ES, and the display does not
come on, it may indicate the batteries need charging.
The “OFF/CHARGING” power switch position is for
use when the batteries need charging or the 630ES is
not in use. As mentioned earlier of course the AC/DC
Battery Charger must be plugged into the 630ES’s
keyed connector to facilitate charging the batteries.
Although the batteries are fully charged prior to
shipment, it may be desirable to refresh the charge
for 24 hours before use. As a rule of thumb, the
630ES requires twice as much time to fully recharge
as the amount of discharge time. For example, if the
instrument was used continuously for 2 hours,

SECTION B - 630ES EXPLOSIVE SAFETY
IGNITER TESTER - SPECIFICATIONS
______________________________________________________________
Table B-2. Specifications
Accuracy: (for 1 year @25°C ± 10°C)
2.0 Ohm range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±0.02% of reading ±0.05% of range
20 Ohm through 200 Ohm ranges . . . . . . . . . . . . . . . . ±0.02% of reading ±0.02% of range
200 KOhm range . . . . . . . . . . . . . . . . . . . . . . . . . . . ±0.05% of reading ±0.05% of range
Temperature Range
Operating 0°C to 50°C
Storage -10°C to 70°C
Temperature Coefficient
2.0 Ohm through 200 Ohm ranges . . . . . . ±0.002% per °C (from 0°C-15°C and 35°C-50°C)
200 KOhm ranges . . . . . . . . . . . . . ±0.005% per °C (from 0°C-15°C and 35°C-50°C)
. . . . . . . . . . . . . . . . . . . .
Instrument Display . . (20,000 count) 4½ digit Super Bright Light Emitting Diodes (LED)
Over-Range Indication . . . . . . . . . . . . . . . . ( select next higher range) 630ES Display flashes
Measurement Update Rate . . . . . Approximately 300ms (~3 per second)
Voltage Protection - Maximum Input . . . . 250VDC or AC without damage
peak
Open Circuit Current Source Compliance Voltage . . . . . clamped at ~1.6 volts ( ± 2% )
Power . . . . (4 "D" 5.0 AHr Heavy Duty) 1.2V rechargeable nickel-cadmium batteries
Fuse . . . . . . 2 ampere fast blo (3 AG type)
AC/DC Battery Charger (Option 630DC) provides 9VDC at 1.1 Ampere nominal
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5" (34.3cm) W x 12" (30.5cm) D x 6"(15.2cm) H
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 lbs net; 15 lbs shipping
Conversion Rate . Approximately 3 per second
Functional Test Section - The 630ES Functional Test Section provides added measurement integrity using a
milliammeter and test resistors to cross check the overall 630ES operation whenever desired. The test
resistors are for cross checking 630ES basic operation and should not be used for calibration purposes.
Simpsontm DC Milliammeter Range - 0-10 mA fullscale, Accuracy ±3%
FTSR1 01-23572 0.1 Ohm 3.0 % Resistor, Tc-50ppm/°C 1/4W
FTSR2 01-23573 1.0 Ohm 3.0% Resistor, Tc- 50ppm/°C 1/4W
FTSR3 01-23574 10.0 Ohm 3.0% Resistor, Tc- 50ppm/°C 1/4W
FTSR4 01-23576 100.0 Ohm 3.0% Resistor, Tc- 50ppm/°C 1/4W
FTSR5 01-23580 100 KOhm 3.0% Resistor , Tc- 50ppm/°C 1/4W
FTSR6 01-23582 190 KOhm 3.0% Resistor, Tc- 50ppm/°C 1/4W
MILLAMPERES
2
4
6
8
10
1.0 OHM
190K OHM

CHAPTER C - REPLACEABLE ITEMS,
OPTIONS AND ACCESSORIES
C-1. Available Accessories and Options
This manual does not list all possible
accessories that AMPTEC RESEARCH is
willing to provide as a support items for the
630ES Explosive Safety Meter Igniter Tester.
Contact the sales department at AMPTEC if you
have a request for an item that is not described
here. Listed below are the options available for
use with the AMPTEC 630ES Explosive Safety
Meter Igniter Tester.
Option 630-BAT: Replacement Battery Pack
The rechargeable NICAD battery pack
installed in the 630ES Explosive Safety Meter
should provide trouble-free operation.
Replacement, however, may eventually be
necessary. The 630ES Explosive Safety Meter
battery pack uses four "D cell" - 1.2V (5.0 AHr
NICAD recommended) installed in a
rechargeable battery pack.
C-2. 630ES Test Lead and Connector Sets
All AMPTEC Explosive Safety - Igniter Tester /
Failsafe Ohmmeter Test Leads and Probe sets
are a minimum 48" length. One end of the test
lead set is terminated with the mating connector
for 630ES Front panel connection port (user
specified). AMPTEC RESEARCH's website
http://www.amptec.com should also provide the
latest information on accessories available.
Option 630-300 : A 4 Terminal Kelvin Clip
Lead Set (630ES compatible)
The option "630-300" is a shielded 48" lead set
terminating in ½" opening Gold Plated 4
Terminal Kelvin clips that is AMPTEC 630ES
compatible. The option "630-300" can clip
easily to wires, pins, and medium size (up to ½"
diameter) conductors. Option "630-300" is the
recommended Kelvin Clip four wire lead set for
the 630ES Series Igniter Testers. The notched
connector end plugs directly into the 630ES’s J1
main front panel connector labeled for “test
leads”.
(photo shows AMPTEC 630ES battery pack)
The reliability of the 630ES battery pack is
estimated to be ten fold better than individual
batteries simply placed in the battery holder.
AMPTEC RESEARCH does not recommend
using individual NICAD batteries in lieu of the
AMPTEC 630ES battery pack, and as such
would be deemed a violation of product
warranty. To order a replacement
AMPTEC630ES Explosive Safety Meter
NICAD battery pack specify AMPTEC part
number "OP630-BAT".

The option "630-400" can clip easily to wires,
pins, and medium size (up to ½" diameter con-
ductors). The notched connector end plugs
directly into the 630’s J1 main front panel con-
nector labeled for “test leads”.
Option 630-305: Separate/Twin Banana Plug
(Red tipped and Black tipped) Cable Set
Option "630-305" is a 48" long replacement
cable set normally supplied as part of the
AMPTEC 630BN Ohmmeter package. The
Option “640-305 has two single banana plugs
(meter and common) terminated with the
630BN style notched connector. One banana
plug is red (Voltage high and Current High) and
one banana plug lead end is black (Voltage low
and Current low) . The 4-wire configuration is
maintained up to the point of the banana plug,
eliminating most cable resistance effects.
Option 630-Plug: For Custom Test Harnesses
Option "630-Plug" is the 630Test Lead Plug
along with 8 gold pin/sockets for custom wir-
ing/missile test harness applications.
Contact the sales department at AMPTEC
RESEARCH (phone [phone] from
inside the USA) if you have need for a special
probe, adapter, lead set, or custom option..
AMPTEC’S engineers have helped customers
with special igniter tester accessory require-
ments. Check with our website which is
http://www.amptec.com for latest AMPTEC
RESEARCH contact (address and phone #
changes) information.
C-1. Available Accessories and Options
This manual does not list all possible
accessories that AMPTEC RESEARCH is
willing to provide as a support items for the
630BN Igniter Tester. Contact the sales
department at AMPTEC if you have a request
for an item that is not described here. Listed
below are the options available for use with the
AMPTEC 630BN Igniter Tester.
Option 630DC: Battery Charger
Option "630DC" is an AC/DC converter that
converts 115VAC line voltage to 9VDC at 1.1A.
The 630 Battery Charger is fitted with the
mating plug that connects to the unit’s J1
connector. One charger is provided as a standard
accessory with every 630ES Igniter Tester .
Replacement Batteries
The rechargeable NICAD batteries installed in
the 630ES should provide trouble-free
operation. Replacement, however, will
eventually be necessary. The 630ES uses four
1.2V cells (5.7 AHr recommended) installed in a
reusable battery box. The batteries are held in
place by a metal retaining plate. When
ordering replacement batteries, please specify
AMPTEC Stock #05-10117, quantity four (4).
C-2. Test Lead and Connector Sets
Option 630-400: 4 Wire Kelvin Lead Set
Option "630-400" is the recommended Kelvin
four wire lead set for the 630 Series Igniter
Testers ( especially for versions that have a 2
Ohm range). Option 630-300 is a shielded 48"
lead set terminating in ½" opening Kelvin clips.
A
B
C
D
E
F
H
G
A= I High
B= V High
C= V Low
D= I Low
E=
F= Ground (-)
G=Chassis Ground
H= +5 V

The AMPTEC 630ES Igniter Tester test leads are normally 48" long. The 630ES uses the water-resistant
ITT Cannon Tridenttm (Test Lead mate) connector on its front panel. Most all AMPTEC 630 series
ohmmeter 4 Wire Kelvin test leads are compatible.
Option "630-304" Gold 4-Wire Kelvin Banana Jack
Test Lead Set ( twin single banana jack version also available)
Option "630-401" Gold 4-Wire Kelvin
Single Point Probe Lead Set are 4 wire
to the base of each tip
Option "630-304"
Gold 4-Wire Kelvin
Clip Test Lead Set
Option "KCS"
Kelvin Clips accept
banana jacks in back.
works with
Option "630-403" is a 4-wire Kelvin
Handheld Probe Lead set terminated with
two handheld probes (2 sharp pointed gold
plated spring loaded tips per probe).
SECTION C: REPLACEABLE ITEMS & ACCESSORY ITEMS CONTINUED
The AMPTEC 630ES Explosive Safety Igniter Tester is compatible with most all 630 series
accessories and test leads. Including the option "PG-401" 4 Wire Kelvin type
Pistol Grip Kelvin Probes (OP PG-401) shown below.
Option "PG-401" 4 Wire Kelvin
Pistol Grip Probes/Test Leads
Option "630-305" twin single banana jack lead set

SECTION D: OPERATION AND USE
_____________________________________________________
D-1. General
This section of the manual contains
complete operating instructions for the
AMPTEC 630ES Explosive Safety Igniter
Tester/ Failsafe Ohmmeter. A description of
the front panel controls, connection
instructions, and the theory behind 4-wire
resistance measurement is discussed in this
section.
D-2. Front Panel Features and Operation
Power Switch
When the front panel power switch is placed
in the OFF/CHARGE position, all power is
removed from the ohmmeter measurement
pins of the J1 connector (see E-6), and the
battery pack is connected to the charging
circuit. When the switch is placed in the ON
position, the battery pack is disconnected
from the charging circuit. In addition the
keyed connector on the 630ES front panel
only allows either connecting a) the battery
charger or connecting b) the test lead set but
not both. The possibility of a common mode
voltage between the device under test and
AC Power ground is therefore completely
eliminated. The operator can not be
concerned if the battery charging adapter is
plugged into the 630ES as it is then
impossible to make any resistance
measurements.
Range Switches
The AMPTEC 630ES input range is selected
by depressing the desired range switch
(silicone boot coated for water resistance) on
the front panel. The pushbutton for the (20
Ohm ) lowest resistance range is just below
the display on the left, (see item 20 of the
630ES Front Panel Diagram.). When a given
range is selected an indicator LED informs
the user. Also note that a resistance range
must be selected after powering up the
630ES in order to place it in an operational
mode.
Calibration Access Screws
Around the perimeter of the 630ES front
panel you will note there are 10 screws
(philips head type) that are used for
calibration access. These screws are meant
to remain intact and should only be removed
by authorized personel (i.e. Calibration Lab
staff).
Function Test Section
The Function Test Section of the 630ES
contains an analog 10 mA fullscale
milliammeter and a variety of test resistors.
With one test lead (i.e. red banana ) plugged
into the meter panel jack and the other test
lead (i.e. black banana lead) plugged into the
common panel jack, the milliammeter will
display the actual test current coming from
the 630ES Igniter Tester.
The test resistors for the Function Test
Section may also be used to verify general
630ES operation. Keep in mind the proper
resistance range should be selected in order
to measure a selected test resistor. You can’t
measure a 1000 ohm resistor on the 20 ohm
range of the 630ES. With one test lead (i.e.
red banana lead ) plugged into the selected
test resistor panel jack and the other test lead
(i.e. black banana lead) plugged into the
common panel jack, the 630ES Igniter
Tester should display a resistance value
close to the labeled value of the resistor.
The 0.1 ohm resistor is commonly used to

test the low end (i.e. linearity) of a given
630ES resistance range. The 0.1 ohm
resistor can be used to check the 630ES’s
zero offset. The AMPTEC 630ES’s zero
adjust knob can be adjusted while whilt the
test leads are connected to the 0.1 ohm
resistor. The 630ES zero knob can be
adjusted until the 630ES display shows 0.1
ohms.
Refer the AMPTEC 630ES to qualified
service personnel (i.e Calibration Lab) if you
suspect (i.e large error) the 630ES
measurement display readings don’t agree
with the resistor values labeled on 630ES
Function Test Section.
AMPTEC 630ES Front Panel Diagram
1. Calibration/Maintenance access screws,
also can be easily protected with a tamper
proof calibration sticker or seal.
2. Purge Valve provides air pressure
equalization to open the 630ES case after a
transit envolving an altitude change if unit
will not easily open.
3. Handles for lifting front plate, once the
access screws have been removed, for
calibration access
4. Single Access Multi-purpose Notched
Main Connector - for either test lead
hookup or connection to the battery charger.
With only one connector to the outside
world, it is physically impossible to do both
at the same time. The power switch (item
#21) must also be in the “Off/Charging”
while the battery charger is connected to
recharge the batteries.

5. Milliammeter for measuring test current
coming from the AMPTEC 630ES
Ohmmeter. Plug one lead into the panel jack
labeled “meter” and the other into the
common panel jack. The Analog
Milliammeter (current meter) is for
measuring actual 630ES test current (0 to 10
milliamperes fullscale). Use of the
milliammeter (+) panel jack and Common
panel jack (-) in the FUNCTION TEST
SECTION with the 630ES test leads
provides the 630ES analog millammeter test
current measurement connection.
6. Negative sign at the front of the digital
display indicates “low battery level” - time
to recharge.
7. Fuse Access - required for general
operation - 2 ampere fast blow type.
8. Zero pot - for adjusting the shorted
resistance offset of the test lead wiring when
in the 2 wire mode.
9. Keylock Switch - “Safe” mode shorts
inputs together (locked “SAFE” with the key
removed), disconnects & isolates any user
inputs from all 630ES measurement
electronics. “Measure” mode switches user
test lead/inputs to the 630ES Explosive
Safety Igniter Tester/Ohmmeter (the key is
required to switch 630ES to the Measure
mode) . Again, if the key is removed the
630ES cannot measure.
10. Input jack for connecting the 630ES
Ohmmeter meter test lead (plug-in red
banana jack) to the analog milliammeter.
11. Input jack of 0.1 ohm test resistor for
checking the lower end or near zero
accuracy of the 2 ohm and 20 ohm range.
12. 1 ohm test resistor for checking the
mid-scale functionality of the 2 ohm range.
13. 10 ohm test resistor for checking the
mid-scale functionality of the 20 ohm range.
14. Input jack for connecting to the 630ES
Ohmmeter common test lead (plug-in black
banana jack). This common jack is also
“Chassis Ground”. The lining of the 630ES
Explosive Safety Igniter Tester case is
completely enclosed in a conductive
shielded Faraday Cage. The AMPTEC
630ES Faraday Cage design provides
additional electronic noise immunity,
Electromagnetic Pulse (EMP) and
Electrostatic Discharge (ESD) protection.
All measurement cabling (i.e Current high,
Voltage high, Current low, Voltage low) are
sheilded. The measurement leads conductive
sheilding is all connected to Chassis
Ground (Pin G of the Single Access
Multipurpose Notched Main Connector
and the Faraday Cage) when the leads are
connected to the AMPTEC 630ES
Explosive Safety Igniter Tester. This chassis
ground common terminal may also be
connected to earth ground at the users
discretion. Chassis Grounding the 630ES
eliminates the possibility of an electrostatic
discharge coming from the 630ES to the
resistance device under test.
15. 100 ohm test resistor for checking the
functionality of the 200 ohm range.
16. 100K ohm test resistor for checking the
functionality of the 200K ohm range.
17. 190K ohm test resistor - if shunted in
parallel during an “Open Circuit” test using
the 200 K ohm range, a shift < 40 counts
means the resistance under test is >200
Megohms.
18. Water Resistant O-ring seal(s) in lid
and under the edge of the front plate.
19. Tight Squeeze Flip Latch Area - pro-
vides a water resistant seal when closed.
While pressing down with palm on corner of
case, flip latch up to open.

20. Resistance Ranges - 2 ohm, 20 ohm, 200
ohm and 200K ohm - silicone boots provide
water-resistance (small LED indicates the
selected range).
21. Power “On or OFF/Charging Switch”
22. Beveled Display Hood and Super Bright
LED Display ( five times brighter than
bright yellow, red or green LEDs).
23. Padlock Hole (i.e. security) while stored
or during transit.
D-3. Fuseholder and Charging System
Fuseholder
The fuseholder is mounted on the front panel
and contains a 2 amp in-line fuse (see item 7
of the 630ES Front Panel Diagram.). This
fuse is designed to protect the internal
battery pack from excessive charging
currents. Replace blown fuses with the
same type and rating only!
The Charging System
The slimline AC to DC battery charger with
connector is a notched connector that mates
with only two of the 8 pin/socket mating
points on the main panel mount connector
(see Main Connector J1 Section E6 for
pinout definitions). The connection is made
on the 630ES front panel (see item 4 of the
630ES Front Panel Diagram shown earlier).
Again the Single Access Multipurpose
Notched Main Connector is for either test
lead hookup or connection to the battery
charger but not both at the same time. With
only one connector to the outside world, it
is physically impossible to do both at the
same time (charge and measure). The power
switch (item #21) must also be in the
“Off/Charging” mode while the battery
charger is connected in order to recharge the
batteries. The charging requirements
supplied to the internal battery pack are
internally stepped down from the 9VDC
@1.1A supplied by the charger. The correct
charging voltage is supplied by the adapter
included with the instrument. Additional
AC/DC Battery Chargers are available as
Option "630DC". Typically an overnight
charge (16 hours) will provide about an 6 to
8 hour continuous powered up life for the
630ES. The 630ES have an internal
ovenized voltage reference the draws a
considerable amount of battery power when
first turned on. If you know you will be
using the 630ES again in 10 to 15 minutes,
you actually conserve battery power by not
turning it off.
D-4. 4-Wire Resistance Measurement
The four-terminal configuration of the
630ES eliminates errors normally caused by
in series test lead resistance and contact
resistances. In many applications the contact
resistance and can exceed the value of the
test resistance by several orders of
magnitude. The 630ES overcomes this
potential error source by providing two
terminals of constant current and an
additional two terminals for high impedance
voltage measurement. The result is a fast,
accurate resistance measurement of the test
resistance, independent of the resistance of
the current carrying leads.
Figure D-1 (below) illustrates how the 4-
wire principle is used to eliminate lead, wire
and contact resistances as potential error
sources. The internal current source
inherently overcomes all series resistance
(within compliance voltage limits) and
delivers a precise constant current. The
internal high-impedance DVM senses the
voltage drop across the test resistance.
There is negligible contact and lead
resistance error created by the voltage
measurement because the high input
impedance of the DVM limits current flow
in the voltage leads.

Figure D-1. Error Sources in Resistance
Measurements eliminated with Four Wire
Kelvin Connections
D-5. Connections
Connections are made to the front panel
terminals using a 4-wire configuration as
described in section D-4. Only use
AMPTEC test leads supplied with the
630ES Failsafe Ohmmeter. When using
AMPTEC test leads, the notched connector
end plugs directly into the single access
notched main connector (see J1 manual
section E-6) of the 630ES. Next turn the
connector clockwise until you feel the
notch or click of the mating connector of
the 630ES. All AMPTEC 630ES leads have
the 4 wire current high, current low as well
as the voltage sense high and voltage sense
low routed to the end of the leads. The 4
wire Kelvin wires then terminate in a pair of
single banana plugs. One banana plug (red)
for current and voltage high, and another
banana plug (black) for current and voltage
low.
The 630ES’s keyed single access connector
also make it extremely difficult if not
virtually impossible during normal operation
to mis-connect measurement leads to the
630ES .
For 630ES leads other than those terminated
with banana plugs, RG-58 Coax Cabling is
used. This insures that using the four wire
Kelvin measurement system - the current is
carried in the largest conductor and that the
voltage input is shielded.
In addition, the 630ES keyed test lead
connector is optionally available for
customized wiring connections , kelvin
clips, cables terminated with spade lugs, and
special banana jacks.
All AMPTEC ohmmeters use a high
impedance voltmeter as part of the
resistance measurement process. This
voltmeter is a highly accurate and stable 4½
digit analog-to-digital converter (A to D).
Unless it is receiving a definite input signal,
the output reading of this A to D is
ambiguous. The display may indicate a
randomly wandering number or it may
indicate an overrange condition. This
unpredictable display may make it seem to
appear that the instrument is experiencing
some sort of malfunction. It is, in fact, just a
characteristic of the voltmeter circuit and
should not be mistaken for a fault in the
instrument.
A flashing display (on and off usally all
zeros) indicates an over-range condition
whenever the terminals are open, or the
resistance under test is a higher value than
the selected 630ES resistance range. By
using a 4-wire Kelvin type lead set or by
shorting the VHI and IHI terminals together
and Vlow and Ilow terminals together the
instrument is in the 2 wire resistance mode.
All wiring including harness wires from the
two wire test connection out - are in series
with the test squib resistance and become
part of the actual two wire measurement
(another potential source of measurement
error if not compensated for) . Many
Ordnance test procedures have the 630ES
user short their wiring harnesses at the very
end (by the squib) and record the resistance

value or offset. Then when the 630ES leads,
including the in-series harness wiring
resistance, is connected to the test squib, the
squib test resistance can be calculated (via
subtraction of the 2 wire harness offset).
That is the 2 wire lead length shorted offset
resistance (without the squib resistance) can
be subtracted for the total resistance
(including the squib resistance) to
determine the actual squib (test) resistance.
The display should indicate a stable reading
when the test leads are securely attached to
the device under test. If the display appears
to be erroneous when connected to the
resistance under test, recheck the test leads
for integrity and cleanliness. If all external
items appear to be functioning properly, the
next step in troubleshooting is to use the
Function Test Section of the AMPTEC 630
series igniter tester. The Functional Test
section contains test resistors of known
value. If a measurement problem appears on
the 20 Ohm range of the meter, test for a
zero offset problem first. Plug the test leads
into the 0.10 test resistor banana panel jack
built into the Functional Test Section of the
meter. If the meter doesn’t display a value
close to 0.1 Ohms adjust the zero knob on
the front of the meter until it does. The zero
adjustment knob only has enough span to
zero out the 630 series test leads. The
meter’s zero adjustment knob wasn’t
designed to zero out a 100 feet of 2 wire
harnessing.
The 10.0 Ohm test resistor is also located
Functional Test Section of the meter. The
10.0 Ohm test resistor can be used for
testing mid-scale performance of the 20
Ohm range. Performing a similar Functional
Test with the meter across the 10.0 Ohm test
resistor should get a reading close to 10.0
Ohms (i.e 9.995 Ohms is OK). If the
630 series Igniter Tester appears OK after
checking the test resistors in the Functional
Test Section then the connect ion problem
must be outside of the 630 series meter (i.e
your wiring harness or the actual device
under test connection.) If the 630 series
meter doesn’t agree with the test resistors in
the Functional Test Section, then the meter
or it’s test leads are most likely broken. If
this case, please contact your local
AMPTEC RESEARCH Service Office, or
call 1-800-350-5105 or [phone]
(International Overseas) or FAX (512) 301-
9303, email [email protected] .
D-6. Failsafe Operation
The AMPTEC 630 series of igniter testers or
failsafe ohmmeters incorporate a constant
current source design that renders them
incapable of delivering excessive voltage or
current to the device under test. The typical
fail-safe current for each range is indicated
under the corresponding range switch on the
630 series meter front panel. Please refer to
section E-6 for a technical description of the
failsafe circuitry specifics.
As a further precaution the 630 series igniter
tester is isolated from the AC line
whenever the POWER switch is in the ON
position.
The 630 series igniter tester receives its
power from an internal rechargeable battery
pack (4 “D” Cell Ni-Cad batteries). The 630
series igniter tester main power switch (see
item 21 of the 630 series igniter tester
Front Panel Diagram) must be in the OFF /
CHARGING position in order to charge the
batteries. Of course, the battery charger must
also be plugged into the unit’s keyed single
access connector. As mentioned earlier the
630 series igniter tester ’s keyed single
access front panel connector allows either
the slim-line battery charger to be connected
or the 630 series igniter tester test leads to
be connected to the 630 series igniter tester
ohmmeter but never both simultaneously.
This “keyed single access front panel
connector” safety feature eliminates any
possibility of the operator measuring with
the 630ES Igniter Tester test leads while
also connected to an AC line powered
adapter.

D-7. Battery Monitoring Circuitry
The 630 series igniter tester display has a ±
polarity display indicator preceding the
unit’s regular 4 ½ digit numeric display.
The negative polarity display LED (see
item 6 of the 630 series igniter tester Front
Panel Diagram) is used as a Low Battery
indicator.
If the low battery LED is illuminated, 630ES
readings should not be trusted. An
overnight recharge should be performed
before using the 630 series igniter tester for
critical testing.
It is possible for the user to receive a low
battery indication on a single range only
(particularly the 20 ohm range), while the 630
series igniter tester remains well within
operating limits on other ranges. Unless the
user observes a continuous low battery
indication during measurement, readings
are still valid.
Notice for Cal Lab: The variable
potentiometer - RV3 is factory adjusted to
have the low battery indicator come on at
4.50 VDC. To make this adjustment, and
remove the fuse from the fuseholder. With
an adjustable DC power supply, set the
power supply output to be 4.50 VDC. Be
sure to observe power supply polarity.
Connect the power supply to the test points
labeled “MAIN” + pos. and - neg. located
in the rear section of the 620A MAIN PCB.
(i.e positive + power supply output to the
anode side). Adjust trimpot RV3 to have the
low battery indicator just come on (negative
sign on display). An increase in power
supply voltage to 4.52 VDC should have the
low battery indicator go out. Finally,
disconnect the power supply, and return the
fuse to the fuse holder in the rear panel.
D-8 Zero Pot
The Zero Pot on the 630 series igniter tester
Front panel (see item #8 on 630 series
igniter tester Front Panel Diagram) is used
to adjust linearity, which effectively adjusts
the “zero” of the meter. The zero can be
adjusted using the “zero knob” per the
maintenance section of this manual. The
zero knob can also be used to counteract the
2 wire resistance offset encountered with
some test lead harnesses. Checking the
630ES “zero offset” should be one of the
first items a user does if one encounters an
unusual or unexpected resistance level.

CHAPTER E GENERAL OPERATION AND DESIGN
E-1. General
The AMPTEC RESEARCH 630ES Igniter
Tester is shown in block diagram form in Figure
E-1. All diagrams and information disclosed in
this chapter is proprietary and is included in
order to make troubleshooting to component
level possible.
The AMPTEC 630 Series Igniter Tester uses
modern solid-state semiconductors exclusively
and digital CMOS circuits extensively to
minimize power requirements and make battery
operation useful and practical. AMPTEC also
maintains a spare parts inventory of all
components found in the 630 tester and it’s
customer service department can also provide
additional assistance in the trouble shooting
process.
E-2. Troubleshooting
Since the 630 Tester is used to test potential
deadly explosive force detonators and warheads
of missiles etc., personnel that are not qualified
to make such electrical repairs on the 630
Tester should not even attempt to remove the
calibration access screws or open the main
panel or effect any repair whatsoever.
Apparent 630 Tester malfunctions can
sometimes be the result of bad test
lead/connection wiring, wrong connections,
misinterpretation of specifications, low battery
levels, and in rare cases due to an incomplete
understanding of the instrument and how to use
it. A thorough review of the operating
instructions for this instrument is recommended
prior to any component replacement. Check to
be sure that cables and other test equipment are
in good working order before attempting to
troubleshoot the 630 series igniter tester .
If you turn on the AMPTEC 630BN, and the
display does not come on, it may indicate the
batteries need charging, or fuse needs replacing.
If the 630ES exhibits problems that cannot be
eliminated by reviewing Chapters B and D, the
following guidelines have been established to
help solve the problem.
E-2-1. Localizing the Problem
Chapter D-2 discusses how to use the
Functional Test Section of the 630 Tester to
help localize the problem. The key to successful
troubleshooting is to localize the problem to a
general electronic parameter as much as possible
before trying to pin the problem down to a
specific component. Certain questions should
be asked such as "Does the problem occur on all
ranges or on a specific range only?". If the 630
Tester does not come on when powered up, did
you check the front panel fuse. The power
supplies for both the current source and the
digital voltmeter electronics are also one of the
first things that should be tested.
As it is not possible to anticipate all failure
modes of the 630 series igniter tester, servicing
personnel should become familiar with this
section to gain a complete understanding of the
internal workings of the ohmmeter.
E-2-2. Component Replacement
If the malfunction is a faulty component, the
accuracy of the 630 series igniter tester can be
maintained only if the 630 is re-calibrated
following the component replacement and the
following precautions are taken:
Use only the specified component or its exact
equivalent. Spare parts can be ordered from
your nearest AMPTEC RESEARCH Service
Center or directly from the factory by referring
to the AMPTEC Stock Number listed in the
Parts Lists section at the back of this manual.
The highest quality 63/37 grade rosin core
electronic grade solder with a 50W or lower
maximum power soldering iron should be used.
Never use an acid core solder as corrosion of
components leads and PCB etch loss can occur.

When soldering, heat the PCB pad and the lead
of the component, not the solder. After several
seconds of the component lead in contact with
the hot soldering iron apply solder smoothly and
evenly onto the PCB pad and component lead
not the soldering iron. Do not touch or move
the replacement part until the solder has cooled.
Cold solder and bad solder joints can cause
more problems.
Use the chassis ground (connect to the common
terminal of the functional test section)
connection - i.e. connect to an earth ground to
avoid a static discharge to a static sensitive
component. Handle all 630 internal components
as if they are static sensitive if you are not sure.
See Next Page for Start of 630 Circuit Descriptions and Functional Diagrams

E-3. Circuit Descriptions
The circuit descriptions which follow are
referenced to Figures E-1, E-2, E-3 and the
schematic diagrams at the back of this manual.
In the following descriptions, references to
integrated circuits are given in the form "IC201-
1", which refers to Integrated Circuit 201, pin 1.
E-4. Analog to Digital Conversion
The A to D conversion is done with a ICL8068
/ICL71C03 chip set. The ICL8068 takes care of
the analog part and the ICL71C03 takes care of
the digital part of the 4 ½ digit 20,000 count
dual slope conversion.
COUNTERS
DISPLAY
COMPARATOR
BUFFER
MULTIPLEXER
ZERO
CROSSING
DETECTOR
INTEG
UUT
CONTROL
LOGIC
INPUT
SWITCH
DC CONSTANT
CURRENT SOURCE
RANGE
SWITCH
MODEL 630ES OHMMETER BLOCK DIAGRAM
COUNTS
PHASE I
I0.00I I0.000 20.00I
4 ½ DIGIT
PHASE II PHASE III
NUMBER OF COUNTS TO ZERO CROSSING
PROPORTIONAL TO VIN
AFTER ZERO CROSSING,
ANALOG SECTION WILL BE
IN AUTOZERO CONFIGURATION
BUSY
OUTPUT
INTEGRATOR
OUTPUT
CLOCK
AZ PHASE l INT PHASE ll DEINT PHASE ll AZ
INTERNAL
LATCH
POLARITY
DETECTED
ZERO CROSSING
OCCURS
ZERO CROSSING
DETECTED
Figure E1 - 630 Conversion Timing Diagram